Effect of Strain Rate on the Mechanical Behavior of Additive-Manufactured Aluminum Alloy after Severe Plastic Deformation

Abstract:

This work presents the mechanical behavior of additive-manufactured AlSiMg alloy after severe plastic deformation (SPD). Equal Channel Angular Extrusion/Pressing (ECAE/P) is a well-known SPD method used for mechanical property improvement via grain refinement in metals. In this study, 8 pass ECAP at 250°C ECAP process is conducted on AlSi₁₀Mg which is manufactured by laser powder bed fusion (LPBF). Tensile tests were conducted at room temperature and at various strain rates to measure the strain rate sensitivity (SRS). With varying strain rate, there was appreciable change in the flow stress levels indicating that the severely deformed alloy exhibits negative SRS. Possible reasons for this mechanical response are explained based on the evolved microstructure to shed light on the parameters governing SRS in additive-manufactured alloys subjected to SPD.

• Periodical: Key Engineering Materials (Volume 1013)
• Pages: 99-104
• DOI: https://doi.org/10.4028/p-tSl4CG
• Online since: May 2025
• Authors: Muhammad Farhan Raza, Serdar Mermer, Amin Radi, Guney Guven Yapici*
• Keywords: Additive Manufacturing, AlSiMg, Aluminum, Laser Powder Bed Fusion, Severe Plastic Deformation, Strain Rate Sensitivity

References

[1] Ngo TD, Kashani A, Imbalzano G, Nguyen KTQ, Hui D. Additive manufacturing (3D printing): A review of materials, methods, applications and challenges. Compos B Eng 2018;143:172–96.

DOI: 10.1016/j.compositesb.2018.02.012

[2] Ni H, Zeng Q, Zhang K, Chen Y, Wang J. Mechanical Properties and Fracture Behavior of Laser Powder-Bed-Fused GH3536 Superalloy. Metals (Basel) 2022;12.

DOI: 10.3390/met12071165

[3] Hosseinzadeh A, Radi A, Richter J, Wegener T, Sajadifar SV, Niendorf T, et al. Severe plastic deformation as a processing tool for strengthening of additive manufactured alloys. J Manuf Process 2021;68:788–95.

DOI: 10.1016/j.jmapro.2021.05.070

[4] Mishra A, Agarwal R, Kumar N, Rana A, Kumar Pandey A, Dwivedi SP. A critical review on the additive manufacturing of aluminium alloys. Mater Today Proc, vol. 47, Elsevier Ltd; 2021, p.4074–8.

DOI: 10.1016/j.matpr.2021.05.698

[5] Chowdhury S, Yadaiah N, Prakash C, Ramakrishna S, Dixit S, Gupta LR, et al. Laser powder bed fusion: a state-of-the-art review of the technology, materials, properties & defects, and numerical modelling. Journal of Materials Research and Technology 2022;20:2109–72.

DOI: 10.1016/j.jmrt.2022.07.121

[6] Van Cauwenbergh P, Samaee V, Thijs L, Nejezchlebová J, Sedlák P, Iveković A, et al. Unravelling the multi-scale structure–property relationship of laser powder bed fusion processed and heat-treated AlSi10Mg. Sci Rep 2021;11.

DOI: 10.1038/s41598-021-85047-2

[7] Shakil SI, Hadadzadeh A, Pirgazi H, Mohammadi M, Haghshenas M. Indentation-derived creep response of cast and laser powder bed fused AlSi10Mg alloy: Air temperature. Micron 2021;150.

DOI: 10.1016/j.micron.2021.103145

[8] Radi A, Duygulu O, Isil C, Yapici GG. On the strain rate sensitivity of a TRIP assisted high entropy alloy. Mater Lett 2023;333.

DOI: 10.1016/j.matlet.2022.133610

[9] Rosenthal I, Stern A, Frage N. Strain rate sensitivity and fracture mechanism of AlSi10Mg parts produced by Selective Laser Melting. Materials Science and Engineering A 2017;682:509–17.

DOI: 10.1016/j.msea.2016.11.070

[10] Olakanmi EO, Cochrane RF, Dalgarno KW. A review on selective laser sintering/melting (SLS/SLM) of aluminium alloy powders: Processing, microstructure, and properties. Prog Mater Sci 2015;74:401–77.

DOI: 10.1016/j.pmatsci.2015.03.002

[11] Picu RC, Vincze G, Ozturk F, Gracio JJ, Barlat F, Maniatty AM. Strain rate sensitivity of the commercial aluminum alloy AA5182-O. Materials Science and Engineering A 2005;390:334–43.

DOI: 10.1016/j.msea.2004.08.029

[12] Yan SL, Yang H, Li HW, Yao X. Variation of strain rate sensitivity of an aluminum alloy in a wide strain rate range: Mechanism analysis and modeling. J Alloys Compd 2016;688:776–86.

DOI: 10.1016/j.jallcom.2016.07.077

[13] Karaman I, Yapici GG, Chumlyakov YI, Kireeva I V. Deformation twinning in difficult-to-work alloys during severe plastic deformation. Materials Science and Engineering A 2005;410–411:243–7.

DOI: 10.1016/j.msea.2005.08.021

[14] Harun HJ, Mccormick PG. Effect of precipitation hardening on strain rate sensitivity and yield behaviour in an Al-Mg-Si alloy

DOI: 10.1016/0001-6160(79)90067-1

[15] Hähner P., On the critical conditions of the Portevin-Le Châtelier effect. vol. 45. Acta Metallurgica Inc; 1997

DOI: 10.1016/S1359-6454(97)00066-9

[16] Mulford RA, Kocks New observations on the mechanisms of dynamic strain aging and of jerky July 1979, Pages 1125-1134

DOI: 10.1016/0001-6160(79)90130-5

[17] Kabirian F, Khan AS, Pandey A. Negative to positive strain rate sensitivity in 5xxx series aluminum alloys: Experiment and constitutive modeling. Int J Plast 2014;55:232–46.

DOI: 10.1016/j.ijplas.2013.11.001

[18] Sajadifar SV Hosseinzadeh A, Krochmal M, Wegener T, Bolender A, et al. On the Friction Stir Processing of Additive-Manufactured 316L Stainless Steel. Advanced Engineering Materials 2022;24:2200384. https://doi.org/.

DOI: 10.1002/adem.202200384